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US8255200B2 - Circuit protection and control device simulator - Google Patents

Circuit protection and control device simulator
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US8255200B2
US8255200B2US12/454,467US45446709AUS8255200B2US 8255200 B2US8255200 B2US 8255200B2US 45446709 AUS45446709 AUS 45446709AUS 8255200 B2US8255200 B2US 8255200B2
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simulator
circuit protection
control device
power circuit
simulated
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US20090299720A1 (en
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Edward Ingraham
David Otey
Rüdiger W. Hausmann
Elie G. Ghawi
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Siemens Industry Inc
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Siemens AG
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Assigned to SIEMENS ENERGY & AUTOMATION, INC.reassignmentSIEMENS ENERGY & AUTOMATION, INC.ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS).Assignors: HAUSMANN, RUDIGER W.
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Abstract

A power circuit protection and control device simulator emulates in real time identical circuit protection and control functions performed by the actual device being simulated and generates real time simulated operational information concerning at least one of the device or the power circuit. A human-machine interface, such as through a web browser, allows a user to input power circuit operational parameters, such as motor current and load, and device variable circuit protection and control operational parameters, such as trip class, ground fault detection or phase unbalance protection. The simulator displays in real time simulated operational information on the human-machine interface. The simulator may be used to simulate operation of an electronic overload relay and an electric motor controlled by the relay.

Description

CLAIM TO PRIORITY
This application claims the benefit of our U.S. provisional patent application entitled “SYSTEMS, DEVICES, AND/OR METHODS FOR SIMULATING EQUIPMENT” filed May 29, 2008 and assigned Ser. No. 61/056,918, which is incorporated by reference herein.
BACKGROUND OF THE DISCLOSURE
1. Field of the Invention
The invention relates to power circuit protection and control device simulators. One embodiment of the present invention enables a user to simulate actual operation of a motor overload relay and electric motor, via a web browser, using at least some of the identical control parameters of the manufactured relay product. The simulator of the present invention is useful for training users in the operation of a control device and testing simulated operation in a non-destructive virtual environment, without risk of physical damage to actual power equipment. By way of example, a user can test intermittent operation of a simulated motor and overload relay under varying load test conditions envisioned in a future factory design, to determine whether the overload relay will trip due to simulated motor thermal overload, without having to configure an actual motor test bed. The simulator of the present invention also allows non-destructive virtual testing of new control functions, such as new thermal modeling protection algorithms prior to bench testing.
2. Description of the Prior Art
Electrical distribution and power circuit designers, engineers, maintenance technicians, equipment specification/purchasing managers and others in the field need to understand the features, functions and operational characteristics of residential, commercial and industrial electrical equipment. Given the complexities of modern electrical equipment components and electrical distribution system design environments, it is desirable to understand, prior to actual construction, how equipment will interoperate once connected to a working system.
In the past, longer construction lead times and relatively fewer variations of relatively simpler electrical equipment allowed designers to use best professional judgment and experience to design and specify electrical distribution systems. In due course, the system would be built and “de-bugged” as necessary in the field in order to achieve acceptable operational performance. Present shorter design and construction lead times, greater variation and complexity of equipment, and high repair and replacement cost of electrical equipment have created demand for pre-construction system performance verification.
One common electrical power system application in industrial and commercial environments is an electrical motor powering an intermittent, varying load. A motor overload relay is interposed between an electrical power source and the motor in order to protect the motor from overload conditions, such as a stalled or locked rotor, and overheating from excessive or rapid intermittent loads that do not allow the motor to cool sufficiently. The overload relay is sized, through equipment performance specification, control settings (i.e., maximum rated steady-state operational, maximum in-rush current during startup, permissible phase unbalance variations, etc.) and empirical testing, to protect the motor from overheating, yet avoid inadvertent nuisance tripping.
In the past, through professional judgment, experience and trial and error, an electrical system designer would attempt to match a motor and overload relay combination to be able to conform to the anticipated system design operational requirements. The designer could consult product specification sheets, time vs. current heat charts and the like to specify a particular rating and adjustment settings of a motor overload relay. Product specification, testing and configuration were heavily dependent upon the empirical experience of the designer. Upon actual construction, the combination would be tested and verified in the field. If the system overheated or was subject to nuisance tripping, different overload relay control adjustment settings would be tested. If performance remained unsatisfactory a different specification overload relay might be needed to replace the one in the initial design.
The time-consuming trial and error specification methodologies and development of designer professional experience had to be passed on to designer trainees. Need has long existed in the electrical system design arts to provide simulation training tools that would enable experienced design professionals to configure system designs in quicker fashion with minimal design corrections and to provide training experience for less experienced design trainees.
In the past there have been attempts to make electrical distribution circuit protection simulation apparatus that would enable a designer to mimic loads on multiple circuit breakers in a distribution system, so that faults could be isolated to the circuit breaker most closely associated with the fault node. Such systems essentially allowed computer-stored time/current charts to be overlayed, so that the correct circuit breaker size could be verified, as well as overload current settings (e.g., ground fault, instantaneous trip and other time/current settings). Time/current data were generally gathered empirically. For example, for a specific design and load capacity of an electric motor, acceptable performance time/current charts were derived so that motor heat capacitance operational limits were understood by designers. Generally such charts were created with conservative operational parameters, so as to minimize risk of motor damage.
As motor control electronics became more sophisticated, microprocessor-controlled overload relays were developed that could digitally model electrical motor heat capacitance and heat transfer in real time. An example of such motor controllers is described in U.S. Pat. No. 5,539,601, “Apparatus and Method for Thermal Protection of Electric Motors”. Motor temperature overload control algorithms described in the patent allowed for more precise, real time evaluation of motor heat capacitance and heat transfer. Rather than select conservative control settings based on imperfect empirical data, the motor controller could more successfully model actual motor operating conditions, and if necessary cause a motor contactor to de-energize power to the motor before the motor became overheated. However, motor controllers of the type shown in U.S. Pat. No. 5,539,601 were intended for field application and not as virtual simulator test beds. Both the control algorithms and control settings had to be bench or field tested. It is desirable to confirm operability of control algorithms and control settings prior to bench testing or field installation.
Thus, a need exists in the art for an electrical power distribution system circuit protection and control simulator that enables designers to test and verify system designs and equipment configuration virtually. A need also exists in the art for an electrical power distribution system circuit protection and control simulator that enables design and maintenance professionals to learn about the interoperability, compatibility and operational characteristics of components in a “hands on” virtual environment.
SUMMARY OF THE INVENTION
These and other needs are achieved in accordance with the present invention by a power circuit protection and control device simulator that emulates in real time identical circuit protection and control functions performed by the actual device being simulated and generates real time simulated operational information concerning at least one of the device or the power circuit. A human-machine interface, such as a web browser, allows a user to input power circuit operational parameters, such as motor current and load and device variable circuit protection, as well as control operational parameters, such as trip class, ground fault detection or phase unbalance protection. The simulator displays in real time simulated operational information on the human-machine interface. The simulator may be used, for example, to simulate operation of an electronic overload relay and an electric motor controlled by the relay. Desirably the simulator is implemented on a web browser for easy use and application by electrical equipment design and maintenance professionals. The simulator of the present invention may be implemented in a client-server networked computer environment.
The present invention includes a power circuit protection and control device simulator having a processor. Memory, accessible by the processor, stores instructions executable by the processor to emulate in real time identical circuit protection and control functions performed by the actual device and generate real time simulated operational information concerning at least one of the device or the power circuit. A human-machine interface, such as a personal computer display, is coupled to the processor and is used for inputting to the processor at least one power circuit operational parameter and at least one variable circuit protection and control operational parameter performed by the actual device. The processor in turn emulates in real time the circuit protection and control functions based on user inputted parameters and displays in real time simulated operational information on the human-machine interface.
In one exemplary application, the simulator device can simulate an electronic motor overload relay and an electric motor. In this application all overload relay operation parameters can be simulated, including: motor load, motor phase unbalance percentage, phase loss, ground fault, full load current, continuous motor operation or intermittent motor operation. Circuit protection and control functions performed by the actual overload relay device are simulated, and include any one of motor overload, thermal overload, short circuit, ground fault or phase unbalance protection or heat capacitance/transfer thermal modeling algorithms. The simulation models employ the actual control algorithms of the real overload relay.
The present invention includes by way of example methods for operating the exemplary overload relay simulator, described above, including inputting to the processor with the human-machine interface at least one power circuit operational parameter and at least one variable circuit protection and control operational parameter performed by the actual device, with the processor, emulating in real time at least one protection and control function performed by the actual device and generating real time simulated operational information concerning at least one of the device or the power circuit. Thereafter the simulated operational information is displayed on the human-machine interface.
Desirably, the simulator of the present invention may include an additional reset feature that enables reset of the thermal modeling simulation, so that additional simulations may be run on a virtual “cooled-down” motor, without the need to wait for additional real time to allow for motor cooling, as would be done in an actual overload relay installed in a field application.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 shows a software block diagram of an exemplary embodiment of the simulator of the present invention;
FIG. 2 shows an exemplary embodiment of the human-machine user interface of the simulator of the present invention, displaying a motor overload relay and electric motor prior to initialization of a simulation by a user;
FIG. 3 shows an exemplary embodiment of the human-machine interface of the simulator displaying a motor overload relay and electric motor simulation in progress; and
FIGS. 4-15 show an exemplary embodiment of the human-machine interface of the simulator displaying screen shots of step-by-step tutorial information window instructions for using features of the simulator.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
After considering the following description, those skilled in the art will clearly realize that the teachings of the present invention can be readily utilized in simulators for other electrical power distribution system circuit protection and control equipment.
1. Simulator Architecture
Referring to the drawings,FIG. 1 is a block diagram of an exemplary embodiment of thesimulator100 of the present invention. Thesimulator100 includes aninformation device110 that in certain operative embodiments can comprise a computer server, a web server, personal computer, work station or personal digital assistant. Theinformation device110 includes aprocessor120 andmemory130 accessible by the processor. Thememory130 can be any form of volatile or non-volatile electronic memory that is capable of storing analog or digital information. Thememory130stores instructions140 executable by theprocessor120 in order to emulate in real time identical circuit protection and control functions performed by the actual device, e.g., an electronic overload relay for an electric motor with motor thermal protection functions. Theinformation device110 has an input/output (I/O)device150 that is capable of communicating with one or more types of interface devices, discussed below.
Theinformation device110 of the exemplary embodiment shown inFIG. 1 also may have anetwork interface160 for communication with one ormore networks170 andother devices172 in communication with the network. Thedevice110 may be a server, including a web server that is in communication withclient computers172 via hard wired communication pathways or in a wireless communication network exemplified by receiver/transmitter174 in communication with a wireless communicationcapable computer176 or wireless personal digital assistant (PDA)178. Thenetwork170 may also include a local area network (LAN), wide area network (WAN), and the Internet. Thesimulator100 desirably can be run in a browser and/or other web-enabled environment, including various forms of JAVAscript-enabled software, or FLASH® player environments, such as those offered by Adobe Systems. Alternatively, thesimulator100 may be a stand-alone system, such as a personal computer, that does not communicate with other devices during simulations.
The I/O device ofinformation device110 communicates with one or more human-machine user interfaces200, that in exemplary embodiments can include a visual display, keyboard and cursor control mouse (not shown). Theinformation device100 can comprise any of numerous circuits and/or components, such as for example, one ormore network interfaces160, one ormore processors120, one ormore memories130 containinginstructions140, one or more input/output (I/O)devices150, and/or one ormore user interfaces200 coupled to I/O device150. In certain exemplary embodiments, via one ormore user interfaces200, such as a graphical user interface, a user can view a rendering of information related to specifying, ordering, designing, selling, manufacturing, and/or delivering a product, such as an electric motor and/or devices associated therewith.
2. Simulator Human-Machine User Interface
FIGS. 2-15 show an exemplary simulator embodiment displayed on human-machine user interface200 computer display screen that is configured to simulate the Siemens ESP200 NEMA solid-state overload relay205, sold in the United States of America by Siemens Energy & Automation, Inc. of Alpharetta, Ga. In thissimulator screen200 embodiment, theoverload relay205 is protecting a three phase, NEMA ratedelectric motor215. As can be appreciated by those skilled in the art, the simulator of the present invention can be configured to simulate other types of circuit protection and control devices in power distribution circuits and protected electrical components other than motors, and the arrangement ofdisplay200 features can be varied. For example, thedisplay200 may include a tutorial orother information window220 for the benefit of users.
In this exemplary embodiment of the simulator, shown inFIG. 2, the user can enter and/or specify any combination of the following circuit protection and control operational parameters through manipulation of a screen cursor via a computer mouse, as if the user were actually configuring anactual Siemens ESP200overload relay205 control switches and buttons:
    • Trip Class DIP switches206 (e.g., 5, 10, 20, 30);
    • Phase Unbalance DIP switch207 (e.g., On or Off);
    • Phase Loss DIP switch208 (e.g., On or Off);
    • Reset Mode DIP switch209 (e.g., Manual or Automatic);
    • Ground Fault DIP switch210 (e.g., On or Off);
    • Full Load Amps via rotary selector211 (e.g., 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 amps); and
    • Overloadrelay reset button212.
Additionally, the power circuit operational parameters can be adjusted by the user through manipulation of motoroperation environment screen200 fields via a computer mouse, such as:
    • Motor load (L1) slider bar225 (e.g., 0-85 A);
    • Phase balance slider bar230 (e.g., 0-100%), where 100% means fully balanced, all phases equal;
    • Motor START button235;
    • Motor STOP button240;
    • Motor starter duration condition highlighted button245 (e.g., Momentary start or Maintained, repeated start);
    • RESETTHERMAL MEMORY button250;
    • SIMULATE GROUND FAULT button255; and
    • SIMULATEPHASE LOSS button260.
As shown inFIGS. 2 and 3, an exemplary simulationrun display screen200 can show simulated power circuit (e.g., motor215) operational status information, including:
    • show the motor in “run” and/or energized mode versus “off” mode via a red or green light and/or dot265;
    • display the motor'sshaft270 slowly turning;
    • indicate theMotor Status275 as “OFF’ or “RUNNING”;
    • present the motor's Runtime inseconds280;
    • show the motor'sTrip Status285;
    • show the overload relay AUTO RESET delay inseconds290;
    • indicate a simulated Thermal Memory value295 (i.e., percentage of allowable stored heat capacitance in the motor);
    • display the load amps on eachphase300; and
    • display the full load amps (FLA) multiple305.
Note that this particularexemplary Siemens ESP200 overloadrelay simulator display200 ofFIGS. 2 and 3 only simulates overload relay class48, with a relay current range of 3-12 A. As those skilled in the art can appreciate, in this overload relay class, the current transformer ratio is 2600 and the burden resistor is 26.10 ohms.
FIGS. 3-15 showexemplary screen200 step-by-steptutorial information window220 instructions for using theoverload relay205. In these figures, the simulator is simulating a Siemens ESP200 overload relay. Screen220-0 is an overview introductory message. Screen220-1 suggests that the user adjust initial control parameter settings on thesimulated overload relay205 with a computer mouse. Screen220-2 teaches the user how to simulate an overload condition, and screen220-3 teaches resetting therelay205 after a simulated overload condition.
The principles of thermal memory (i.e., motor retained heat capacitance and heat transfer) are taught in screen220-4. Note that the availability of the RESETTHERMAL MEMORY button250 feature allows the user to wipe the thermal memory to simulate motor cooling to ambient temperature so that the user may promptly re-initiate simulated motor operation. Without this feature the motor thermal modeling algorithms utilized in the real Siemens ESP200 overload relay would not allow a real motor to start until sufficient time has elapsed to allow for ambient motor cooling.
Simulated phase loss and ground fault are taught in screens220-5 and220-6, respectively.Relay205 auto reset features are taught in screens220-7 and220-8. Phase unbalance protection and control features are taught in screens220-9 and220-10. Screen220-11 invites the user to experiment with the overload relay control settings and different motor operational parameters for additional training and familiarization.
3. Simulator Operation
Thesimulator100instructions140 stored in thememory130 enableprocessor120 to emulate in real time the circuit protection and control functions performed by the actual device being simulated, based on user-inputted protection settings and power circuit operational parameters.Simulator100 operation will now be explained with reference to the exemplary Siemens ESP200 overload relay described above and theuser interface200 configuration settings shown inFIGS. 2 and 3.
Once the user clicks on theSTART button235, thesimulator100 can then calculate the simulated motor currents, as follows:
    • L1 specified by user (slider bar225)
    • L2=L1
    • L3=L1* Phase Balance specified by user
For each of the motor's3 phases, thesimulator100 can calculate N, the thermal increment per time period, from the following equation:
N(L1)=I_Motor(L1)×R_Burden×2n_current_transformer×π×510kΩ×4μA×9450
where:
    • N(Lx)=the thermal increment per time period for the specified phase;
    • I_Motor(Lx)=the motor current (amps) for the specified phase;
    • R_Burden=the burden resistance, which can depend on the overload relay class;
    • N_current_transformer=current transformer ratio, which can depend on the overload relay class; and
    • the 510 kΩ value, 4 μA value, and 9450 constant are associated with this model overload relay.
Thesimulator100 can then calculate A_max, the maximum periodic thermal increment from the following equation:
A_max=max(N(L1),N(L2),N(L3))
Thesimulator100 can then calculate P_Max, which can reflect the motor current unbalance and is zero if the phase balance is 100%, from the following equation:
P_max=max(abs(N(L1)−N(L2)),abs(N(L2)−N(L3)),abs(N(L3)−N(L1)))
Next thesimulator100 looks up Tw from the following table stored inmemory130, which can recalibrate the algorithm to execute once each 500 milliseconds versus the original 192 milliseconds, and/or can alter the calculation to account for the Trip Class for this particular overload relay.
Trip classTw
52.9
102.9/2
202.9/4
302.9/6
Using the full load amperage (FLA) value specified by the user withselector switch211, thesimulator100 can select a threshold from the following table:
FLAThreshold
34832
46368
57936
69616
711344
813024
914544
1016240
1117648
1219168
Next, thesimulator100 can iteratively calculate motor model (“MM”) values at each 500 millisecond interval, as shown in the following equations. This calculation can estimate the exponential heating effects of the current flowing through themotor215. If the MM value exceeds the threshold, thesimulator100 can simulate a trip of theoverload relay205. When therelay205 trips, thesimulator100 can drop the motor current to zero and the calculated MM value can gradually decrease, just as would occur in an actual motor.
MM0=0
MM1=MM0+Tw*(−MM0/128+A_max/2+P_max/4)
MM2=MM1+Tw*(−MM1/128+A_max/2+P_max/4)
MM3=MM2+Tw*(−MM2/128+A_max/2+P_max/4)
And so on.
When, for example, the phase unbalance is to approximately 70% or greater and the value of the phase loss variable is switched to “On” (DIP switch208), thesimulator100 can simulate a phase loss and an associated trip. Likewise, when, for example, the value of the ground fault variable is switched to “On” (DIP switch210), the simulator can simulate a ground fault by pressing SIMULATE GROUND FAULT button255 and thereby initiate a simulated associated trip.
Thus, after clicking theSTART button235, the user can observe the motor control indicators for values generated by the simulator, includingload amps300, full load amperage (FLA) multiple305,motor status275,motor run time280,trip status285, auto resettime290 andthermal memory percentage295.
Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, with respect to an exemplary motor overload relay and electric motor simulator, those skilled in the art can readily devise many other varied simulator embodiments for other circuit protection and control devices and other electrical equipment within a power circuit that still incorporate these teachings.

Claims (22)

1. A simulator for a power circuit protection and control device comprising:
a processor;
memory coupled to the processor, the memory storing instructions executable by the processor to simulate in real time an operation of the power circuit protection and control device and to simulate in real time a coupled power circuit, the simulator replicating at least one circuit protection and control function performed by a non-simulated power circuit protection and control device;
a human-machine graphical user interface coupled to the processor for inputting to the simulator at least one operational parameter of the power circuit and at least one operational parameter of the non-simulated power circuit protection and control device; and
wherein the processor simulates in real time the at least one circuit protection and control function based on the inputted parameters, generates in real time simulated operational information of the circuit protection and control device and displays the real time simulated operational information on the human-machine graphical user interface.
8. A simulator for a power circuit protection and control device comprising:
a processor;
memory coupled to the processor, the memory storing instructions executable by the processor to cause a software application operating within a web browser to simulate in real time the operation of the power circuit protection and control device and to simulate in real time a coupled power circuit, the simulator replicating at least one circuit protection and control function performed by a non-simulated power circuit protection and control device;
a graphical user interface within the software application for inputting to the simulator at least one operational parameter of the power circuit and at least one operational parameter of the non-simulated circuit protection and control device; and
wherein the processor simulates in real time the at least one circuit protection and control function based on the input operational parameters, generates in real time simulated operational information of the circuit protection and control device, and displays the real time simulated operational information within the web browser.
15. A method for simulating the functioning of a circuit protection and control device the method performed by a simulator for simulating in real-time the operation of the circuit protection and control device and for simulating in real time a coupled power circuit, the simulator replicating at least one circuit protection and control function performed by a non-simulated power circuit protection and control device, the simulator having a processor, an associated memory for storing instructions executable by the processor to perform the simulation and information generation functions, and a human-machine graphical user interface coupled to the processor, the method comprising:
inputting to the processor with the human-machine graphical user interface at least one operational parameter of the power circuit and at least one operational parameter of the non-simulated circuit protection and control device;
with the processor,
simulating in real time at least one protection and control function performed by the circuit protection and control device;
generating real time simulated operational information concerning the circuit protection and control device; and
displaying the real time simulated operational information with the human-machine graphical user interface.
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